WIXOM, MI, July 2025 — Integrated Systems Design (ISD), a distinguished systems integrator and OEM provider of advanced warehouse automation solutions, announces its comprehensive initiative to revolutionize supply chain resilience through strategically curated "Made in America" automation partnerships. This groundbreaking approach addresses mounting concerns over international supply chain vulnerabilities while delivering unprecedented operational excellence.Supply Chain Sovereignty Emerges as Critical Business ImperativeContemporary enterprises face escalating challenges stemming from protracted international supply chains, geopolitical instabilities, and pandemic-induced disruptions. ISD's revolutionary approach eliminates dependency on overseas manufacturing networks, establishing robust domestic partnerships that guarantee supply chain continuity and operational predictability. "Patriotism transcends sentiment—it embodies strategic wisdom," declares Ed Romaine, VP Marketing at ISD. "Our domestic manufacturing alliances eliminate intercontinental shipping delays, customs complications, and communication barriers that perpetually plague international sourcing strategies."Technological Prowess Meets Manufacturing ExcellenceISD's meticulously crafted portfolio encompasses cutting-edge automation technologies exclusively sourced from a number of leading American manufacturing powerhouses:UltraStore Mid-Load ASRS represents tried and true engineering achievements in automated storage solutions. This domestically engineered system optimizes mid-range applications requiring high-density storage coupled with lightning-fast retrieval capabilities. Superior technical support, expedited software updates, and streamlined system modifications distinguish this American-manufactured solution.Kardex Remstar Vertical Lift Modules maximize storage capacities through vertical storage optimization. These systems transform limited floor space into high-density storage capacity while delivering requested inventory directly to ergonomic workstations, dramatically enhancing productivity metrics.URBX ASRS showcases next-generation robotic ASRS storage system. These modular, scalable systems adapt seamlessly to evolving operational requirements, featuring real-time optimization algorithms that maintain peak performance regardless of fluctuating demand patterns.Raymond Material Handling Equipment continues decades-long traditions of American manufacturing excellence. Their product lineup encompasses traditional counterbalance forklifts, reach trucks, order pickers, and specialized narrow-aisle equipment designed for high-density storage environments.Reflex Robotics introduces groundbreaking humanoid automation from Brooklyn, New York. Founded by MIT alumni with prestigious experience from Tesla, Boston Dynamics, and Amazon, Reflex delivers cost-effective warehouse and manufacturing general-purpose robotics achieving operational capability within sixty minutes of deployment. Their affordable pricing structure—below annual operator salaries—democratizes humanoid automation across diverse warehouse operations.Strategic Advantages Compound Through Domestic PartnershipsISD's "Made in America" approach delivers multifaceted benefits extending beyond equipment procurement: Supply Chain Resilience: Eliminates international shipping vulnerabilities, port congestion delays, and customs complications Quality Assurance: Domestic manufacturers operate under stringent regulatory frameworks ensuring consistent, superior products Rapid Response Support: Time zone alignment, linguistic clarity, and cultural familiarity accelerate technical support resolution Regulatory Compliance: Intimate knowledge of American building codes, safety regulations, and integration standardsOptimalOps-Process™ Maximizes Automation Investment ReturnsISD's proprietary OptimalOps-Process™ framework orchestrates seamless integration across multiple automation technologies. This comprehensive eight-step methodology ensures optimal equipment selection, strategic implementation, and sustained operational excellence while maintaining vendor-neutral flexibility.Partnership Excellence Drives Sustained SuccessAs an OEM-agnostic systems integrator, ISD leverages extensive partnerships with premier American manufacturers to deliver customized solutions precisely matching operational requirements. This collaborative approach eliminates single-vendor limitations while ensuring unified system performance across diverse automation components. "Our domestic partnerships transcend transactional relationships," emphasizes Ed Romaine, VP Marketing at ISD. "We cultivate enduring alliances that deliver sustained value through comprehensive training programs, reliable technical support, and predictable upgrade pathways."Market Leadership Through InnovationISD's commitment to American manufacturing excellence positions clients advantageously amid intensifying global competition. Domestic automation solutions provide strategic stability, operational reliability, and performance consistency that international alternatives cannot match.Discover Revolutionary Automation SolutionsOrganizations seeking to mitigate supply chain risks through Made in America warehouse automation technologies are invited to schedule complimentary consultations exploring ISD's comprehensive capabilities and strategic advantages.About Integrated Systems Design - ISDIntegrated Systems Design is a comprehensive systems integrator of automated solutions for warehouses, manufacturing, distribution, retail, and wholesale applications, improving processes and productivity while reducing operational costs. Whether providing consulting services to meet current issues or developing future scalable plans to address industry challenges, ISD creates value for a broad range of industries by tailoring systems to clients' specific requirements.ISD expertise ranges from handling, storing, and picking pieces (eaches), cases, pallets, build lines, and special or custom handling solutions. Products and services include automatic storage and retrieval (ASRS), AMR, conveyor, robotics, batch stations, shuttles, pick-to-light, carousels, vertical lift modules (VLMs), controls, and software (including inventory management, WCS, WMS, and MES).ContactEd RomaineVP Marketing & Business Development215-512-2613eromaine@isddd.com

Onboard charging solution allows lithium-ion powered equipment to charge from standard 120- and 240-volt electrical outlets, enabling more operations to leverage electric forkliftsGREENVILLE, N.C. (July 10, 2025) – Hyster announces product of the year honors for its onboard charging solution, with Plant Engineering magazine recognizing the solution with a bronze award in the electrical, power and lighting category. Available on several counterbalanced Hyster® forklifts with integrated lithium-ion battery power, the onboard charging solution allows trucks to be charged using standard, commonly available electrical outlets, rather than requiring dedicated higher-capacity charging infrastructure.“Onboard charging helps address a major challenge that has prevented some operations from taking advantage of lithium-ion power,” says Josh Eby, Global Product Manager, Hyster. “The flexibility to simply plug into a common electrical outlet makes electric forklifts a stronger fit for a much broader range of applications, and this recognition by the readers of Plant Engineering further validates our approach to making electric forklifts more accessible.”The onboard charging option is available on several Hyster lift trucks with lift capacities ranging from 4,000 to 8,000 pounds. This charging flexibility makes lithium-ion-powered forklifts a stronger fit for applications with intermittent charging availability, like agriculture and construction, or lower-hour applications that do not require fast charging, like retail and light manufacturing. It also enables businesses to rent electric forklifts without having to alter their electric infrastructure, and even enables recharging via generator when power is unreliable or unavailable.This onboard charging option includes a charging cable with a 240-volt 50-amp connection, adaptors for both 240-volt 30-amp and 120-volt 12-amp plugs, and an out-of-the-way storage bin located to the left of the seat for all cables and adaptors. Depending on the forklift model, operators could expect to get about one hour of medium-duty usage from as little as a 40-minute 6kW (240-volt) charge or a two hour and 40-minute 1.4kW (120-volt) charge. The addition of the onboard charging option does not affect the ability for units to charge quickly via typical offboard chargers.About HysterHyster is a leading worldwide provider of Hyster® forklift truck and container handling solutions for the toughest, most intense industries on earth. The company designs and manufactures an industry leading, comprehensive range of material handling equipment, meeting the unique demands of everything from fast-paced industrial warehouses and manufacturing facilities to the most demanding, heavy-duty applications like ports and terminals. Backed by a dedicated, global dealer network and nearly a century of material handling experience, Hyster is the trusted resource customers can count on for technology tough enough for their worksites and proven solutions that keep critical operations moving.Hyster Company is a division of Hyster-Yale Materials Handling, Inc., a wholly owned subsidiary of Hyster-Yale, Inc. (NYSE:HY) which is headquartered in Cleveland, Ohio and operates globally.ContactJennifer MeyersHyster Company252-481-1354jennifer.meyers@hyster-yale.com

Fleet of reach trucks, order pickers power new, high-density facility that manages 80% of electronics maker's annual order volumesGREENVILLE, N.C. (July 9, 2025) – Yale Lift Truck Technologies announces that its work optimizing warehouse operations at a new Hamilton Beach facility in Byhalia, Mississippi has been recognized as a Top Supply Chain Project by Supply & Demand Chain Executive. Yale recommended a switch from a lift truck fleet powered by internal combustion engines (ICE) to an electric fleet, with equipment recommendations tailored to support the transition away from floor-level, slip sheet storage to high-density, narrow aisle racking. Ultimately, the new facility helped Hamilton Beach reduce product damage by 80% and ship more than twice as many direct-to-consumer orders annually compared to their previous facility.“Being a warehouse lift truck provider is about far more than just selling equipment or pushing certain technology,” says Brad Long, Global Activation Manager, Yale Lift Truck Technologies. “It’s about thoroughly understanding the operation and finding solutions that best fit where they want to go. Our work with Hamilton Beach is proof of our ability to help businesses evaluate current and future requirements, and build a best-in-class warehouse operation from the ground up.”Prior to the move, Hamilton Beach was working in a 1.2-million square foot facility that struggled with disorganization and congestion that hindered productivity and led to about $2 million in annual product damage. By moving to racking, with about 80% of that being double deep, Hamilton Beach was able to significantly increase storage density while reducing product damage by 80% in the new facility.The new storage configuration and lift truck fleet also helped Hamilton Beach maintain a strong safety record, with zero OSHA-recordable incidents through the first eight months of 2023. In the previous facility, operators used counterbalanced lift trucks to navigate a bulk storage layout that afforded them limited visibility, with operators straining to see around loads. But at the new facility, the racking configuration and side stance of the stand-up reach truck models enable operators to see more easily, enhancing operator comfort and helping to reduce the risk of lift truck accidents.To best service the narrow-aisle racking configuration, Yale recommended a fleet of 51 electric lift trucks, including 33 reach trucks and 12 low-level order pickers. Even with a three-shift, 20-hours-per-day operation, opportunity charging during breaks and gaps between shifts made it possible for the trucks to remain operational throughout the entire day without redundant units. Each truck runs approximately 50% longer during a week than its ICE counterpart in the previous facility. Emissions from the new fleet are greatly reduced compared to the previous ICE trucks, and the efficiency improvements of the building drove a 75% reduction of utility costs – even with the need to charge the new trucks.Black Equipment, a certified Yale dealer, offers 24-hour on-call service and local parts availability for Hamilton Beach, helping to reduce downtime and keep business moving. An on-site technician is also on hand to help with regular maintenance, repairs, warranty claims and more.“I’ve been in supply chain for 30 years, and at previous companies, we’ve had difficulty getting certain equipment serviced. The fact that we have Black Equipment and Yale as a turnkey provider is huge,” says Mike Bunge, Vice President, Global Supply Chain and Operations, Hamilton Beach. “And to top it off we now have the most advanced lift truck technologies for a world-class operation.”About the AwardSupply & Demand Chain Executive’s Top Supply Chain Projects award program profiles innovative projects that are designed to optimize, automate, streamline and improve supply chains.About Yale Lift Truck TechnologiesYale Lift Truck Technologies leverages over a century of material handling experience and substantial investment in innovation to bring the most advanced technology-driven lift truck solutions to market. The company offers a full line of award-winning lift trucks, including reach trucks, order pickers, turret trucks, pallet jacks and trucks, pallet stackers, tow tractors and counterbalanced forklifts, as well as powerful operator assist solutions, proven robotics and a wide range of power sources to help customers adapt to today’s demanding supply chain. Yale and its independent dealer network support these solutions with comprehensive after-sales service, parts, financing and training.Yale Lift Truck Technologies is a division of Hyster-Yale Materials Handling, Inc., a wholly owned subsidiary of Hyster-Yale Inc. (NYSE:HY) which is headquartered in Cleveland, Ohio and operates globally.ContactBrad LongYale Lift Truck Technologies252-412-3652brad.long@hyster-yale.com

The challenge was to create a safety net barrier acting as a door to protect both products as well as employees in a warehouse setting. In addition the door needed to be accessible to the driver of a fork lift from the ground level.

The Hänel Lean-Lift as a high-speed shipping systemWhen it comes to tools, the experts at Productivity Inc. can provide customized solutions for the metalworking industry. In addition to consulting, customer care, service and maintenance,Productivity Inc. delivers tools and tool holders to customers throughout North America. Fast shipping from the company’s site in Minneapolis is supported by three Hänel Lean-Lifts® that are used to store more than 10,000 items.The Hänel vertical lifts are equipped with multifunction containers, making them ideal for automated small parts storage. Job orders are displayed directly on the HänelSoft® terminal and can be processed there.The high-speed version of the Hänel Lean-Lift® quickly brings stored items to the retrieval area on request.If the items needed for a particular order are located in various lift systems, picking performance can be boosted even more through parallel system operation.Thanks to digital compartment and sub-level indicators, even storage positions in very small configuration layout patterns can be identified easily. The combination of all these features ensures that orders are filled and shipped in record time – without errors.Orders are filled directly opposite the system access points, where they are also packed for shipping. Order confirmation is entered in the systems using barcode scanners. Another Hänel Lean-Lift® located in a different area of the warehouse is also integrated in the storage solution.Productivity Inc. quickly recognized the high quality of Hänel technology through the reliable performance delivered by the storage systems

Ultra-compact storage in the Hänel Lean-Lift frees up valuable floor space for production processesDIRTT is a company specializing in the prefab construction of interior spaces and employs 85 people at its site in Phoenix, Arizona. A compact Hänel Lean-Lift® in the production area is used for the heightoptimized storage of hardware, bolts, brackets, and similar items.The high-speed version of the Hänel Lean-Lift® serves as the central distribution system for production at DIRTT. Vertical storage from Hänel means that fewer high-bay racks are needed. What’s more, efficiency and ergonomics have been optimized.Specially designed Hänel multifunction containers ensure neat and compact item storage. Systematic organization of diverse items is guaranteed with flexible container dividers and configuration options. The Hänel Lean-Lift® provides maximum height-optimized storage capacity. The compact Hänel system frees up floor space for other processes and thus reduces costs.Parts needed in the production area are picked from the Hänel Lean-Lift® on demand. This just-in-time principle keeps production processes lean and smooth – there is no need for buffer storage.Fast and error-free order picking with Hänel Pick-o-Light-VarioEmployees use the Hänel MP 12N controller and a barcode scanner to start the picking process. The containers holding the requested items are brought to the retrieval point automatically. Hänel Pick-o-Light-Vario® shines a light beam on the requested items for easy identification. This helps prevent human errors and mix-ups.The integrated management functions of the Hänel MP 12 N ensure constant inventory monitoring of all items in stock. This real-time inventory means that replenishment takes place at the right time to prevent item outages.DIRTT has been very satisfied with the Hänel intralogistics solutions at its headquarters in Calgary, Alberta, Canada. That’s why the company successfully integrated a Hänel Lean-Lift® to optimize processes at the Phoenix site in the US

This is a paid advertisement. Since 1977, PFlow Industries has revolutionized vertical material handling, delivering over 20,000 custom-built vertical conveyors worldwide. From small packages to massive 100,000 lb loads, see how PFlow’s innovative, tailored solutions solve any lifting challenge—enhancing safety, efficiency, and productivity across countless industries. Watch now to see PFlow in action!

This is a paid advertisement.Simlog Forklift and Reach Lift Truck Personal Simulators have surpassed 1,000 setups in operator training programs worldwide. Today, Simlog has added Stand Up Counterbalanced Lift Truck Personal Simulator as our newest product for operator training simulation in narrow aisles, to improve stand up material handling work from dock to stock. A good lift truck operator is a safe lift truck operator, and for this reason, Simlog has developed unique new functionality to make collisions visible as they occur during an exercise with the Stand Up Counterbalanced Lift Truck Personal Simulator.  With Simlog’s world-class simulation graphics, simulation physics, instructional designs, and multi-display functionality together provide unmatched operator training help.Test drive our Personal Simulators at ProMat Booth N6015 to experience how training time can be reduced by 50% at the onboarding step for new lift truck operators, and how the same simulator setup provides post-incident upskilling, to save real costs in the real world.Watch Training Simulation Best Practice Examples in Action: Exclusive Video for the MHI Community

This is a paid advertisement. Simlog Forklift and Reach Lift Truck Personal Simulators have surpassed 400 setups hard at work in operator training programs worldwide. Genuine industry-focused training simulation, and multi-display setup options, deliver skills development for employees the way real lift truck operations are meant to be. Discover how a global automotive parts supplier has cut training time by 50% at a key onboarding step for new lift truck operators. The same simulator setup supports post-incident retraining, raising safety and productivity of the entire lift truck operations team. Watch best practice examples of simulator setups in action with multiple displays.

To complement a new educational video, thought leaders representing the Protective Guarding Manufacturers Association (ProGMA), an MHI product group, discuss the importance of protecting personnel, equipment, and inventory in industrial facilities.ProGMA has recently launched the second in a series of videos about the importance of protective guarding products in the material handling industry. The video titled “Proper Safeguarding for Elevated Work Platforms” followed the inaugural, educational video titled, “Essential Safety Barriers for Automated / Robotic Workcells”. (http://www.mhi.org/progma/videos)Here, representatives of member companies expand on the themes explored within the latest video in the group’s first blog.Before we start, says Arlin Keck, corporate research and development engineer at Steel King (a manufacturer of pallet racks, mezzanines and guardrails), it’s important to clarify what we mean by “mezzanine” in this context. “The technical term for what my company and other members make is work platforms. Mezzanine was an old term for these systems; however, the word mezzanine had to be dropped because mezzanine, as defined in the building codes, refers to a specified type of floor within a building structure and carries with it added requirements for fire safety, egress, parking, and so on,” Keck explains.A typical work platform is design to support the site-specific load that will be placed on the floor, be it palletized loads, pallet jacks, foot traffic, work equipment, filing cabinets, racking or shelving units, to name just a few possibilities.Keck says that the main purpose of an elevated work platform is to add additional floor space into a building or room by taking advantage of surplus ceiling clearance that may exist in a warehouse or manufacturing facility. Aaron Conway, president at Mezzanine Safeti-Gates Inc. (a manufacturer of safety gates to secure the ledges of pallet drop areas on mezzanines and rack picking systems), says, “A company that has utilized all of its ground space can build upward. An elevated platform allows one to use the space for workflow or to store product.”As Hue Schlegel, director of marketing at Wildeck Inc. (a manufacturer of mezzanines and work platforms), puts it, “Move up, not out.” He adds, “Depending on the available height in a building, platforms can be one, two, or three levels high, with the most common height being 10 ft. top-of-deck and supporting a floor load of 125 lbs. per square foot. Their length and width are only limited by facility size.” Importantly, he explains, they cannot occupy more than two thirds of a fire-rated area within a building.Keck says work platforms are also used to create catwalks between separated platforms, and to serve as sortation and conveyance areas for mechanized systems. Conway agrees, adding, “Companies that supply elevated work platforms can fabricate them in virtually any configuration. They can be designed to accommodate specific workflow operations or to fit with existing structures in the building.”Industrial buildings are getting bigger and elevated work platforms are scaling up with them. Say, 50 years ago, facilities were much smaller and ceilings lower so there were fewer requirements for elevated platforms. Further, the equipment to load at such heights didn’t exist. Now, the capability of equipment is greater and taller structures are being utilized as a result. Within them, work and storage takes place on multiple levels.These multi-level work platforms present a danger of personnel and objects falling from height.As the latest video warns, the pallet drop area of elevated work platforms can lead to accidents if the ledge is open without adequate guarding. Falls to lower levels cost employers $5 billion annually in compensation claims in the U.S. alone. OSHA reports that it costs on average 16 lost working days per injured employee.Conway says, “Falling from an elevated level, whether it be people or products, is a serious danger and both should be addressed proactively, securing the situation before an incident occurs.” Schlegel adds, “The worst case, of course, is death; while the best scenario is that a worker survives a fall from the typical mezzanine height of 10 ft. sustaining only broken bones, fractures, and other injuries from hitting the concrete floor below. It is a serious matter not to be taken lightly.”Traditional railing or guarding systems are effective at preventing falls from height as long as they include a kick plate that is installed in conjunction with ANSI MH 28.3-2009. Adding netting or expanded metal and safety products to traditional railing systems provides added protection by capturing small objects that might otherwise fall into the work area below.OSHA Standard 1926.502, meanwhile, requires paneling or screening where tools, equipment, or materials are piled higher than the top edge of a toe-board or kick plate. ProGMA members also manufacture both netting and wire mesh panels that comply with that standard.However, David Brentz, chairman of ProGMA and vice president of member company Industrial Netting (a manufacturer of plastic netting), says, “That’s only a minimum requirement; added protection is financially prudent. The cost to install netting or wire screens around the perimeter of an elevated work platform pales in comparison to the cost of a single lost time accident. ProGMA members offer several simple, cost effective solutions to protect employees below loose objects that may fall or be kicked off work platforms.”Conway says, “In the past, properly guarding a pallet drop area or installing netting or wire was something that would be retrofitted, either after an incident occurred or after someone pointed out the issue. Designing proper safety guarding for the structure at the time of purchase makes for a much better fit; when retrofitting, there is often insufficient room for proper guarding and concessions have to be made. But, it is important to note that even if proper guarding wasn’t designed with the structure, it still should be installed. There are companies in the ProGMA that can customize solutions to fit these areas.”He continues, “Don’t confuse luck with judgment. If I visit a facility that was built, say, 20 years ago, I’m sure to find open pallet drop areas or insufficient guardrails. Just because these areas have been around for a while isn’t a reason not to properly secure them. I’ve heard the line, ‘Well, we’ve been doing it this way for 20 years and nobody has gotten hurt’. To that I say, ‘You’ve been lucky!’”Schlegel says, “The biggest safety risk is when a forklift access gate on mezzanine is left open creating a fall hazard for someone off-loading a pallet at the upper level. There are many products, provided by ProGMA members, that prevent the gate from being left open or that keep the operator at a safe distance, which should always be installed.”ANSI says, “Any gate that provides an access opening through the guards for the purpose of loading and unloading material onto a work platform shall be designed such that the elevated surface is protected by guards at all times. Gates that swing open, slide open, or lift up, leaving an unprotected opening in the guarding are not acceptable.”Dual gate systems such as a rolling gate ensure that the operator is separated from the ledge as well as the load. A pivoting gate ensures the operator is never exposed to the ledge and does not require him or her to walk near an open ledge to operate the gate.Unfortunately, sometimes it can take an incident and a facility to be shut down during an investigation for companies to understand the serious financial consequences of a workplace injury. There are many other companies that understand the risks and proactively secure their work areas. These diligent companies end up ahead in the long run:1. They typically get better solutions because they had the time to design them correctly;2. They get a better price because they can take their time and research the solutions;3. Safety solutions are in place before they need them.Conway concludes, “The large majority of people don’t want to get hurt and are not acting recklessly on the job. Typically, they are performing a repetitive operation, and in their process miss a step or push something too far and someone gets hurt. Proper guarding should be in place to prevent injury if this happens.”About ProGMAThe Protective Guarding Manufacturers Association (ProGMA) members are the industry’s leading suppliers of fixed protective guarding products designed to protect personnel, equipment, and inventory in industrial facilities. Member companies meet regularly to review, discuss, and revise the standards for design and performance of protective guarding products used in the material handling industry. ProGMA member companies are committed to the development, maintenance, and publishing of industry standard specifications for these systems. Visit the website at http://www.mhi.org/ProGMAAbout MHIMHI is an international trade association that has represented the material handling, logistics and supply chain industry since 1945. MHI members include material handling and logistics equipment and systems manufacturers, integrators, consultants, publishers and third-party logistics providers. MHI offers education, networking and solution sourcing for their members, their customers and the industry as a whole through programming and events. The association sponsors the ProMat and MODEX expos to showcase the products and services of its member companies and to educate manufacturing and supply chain professionals. http://www.mhi.orgContactAnupam Berry Boseabose@mhi.org704-676-1190

The Protective Guarding Manufacturers Association (ProGMA) has published a blog to supplement its latest video on safety at pick modules. The video can be viewed at mhi.org/progma/videos.Here at ProGMA, we have produced a series of educational videos on protective guarding equipment in the material handling industry. ProGMA members provide fixed protective guarding products to protect personnel, equipment, and inventory in industrial facilities. A variety of such items are designed for installation at pick modules, which are multi-level structures typically constructed out of pallet rack that allow multiple pallets of product to be stored, broken down, picked, and packaged into specific orders for shipping.Our video is targeted at end users, system integrators, material handling warehouse design consultants / engineers, distributors, and safety professionals in manufacturing and distribution centers in the material handling industry, as well as students studying the sector. Many household and industrial goods we interact with every day were once stored or passed through a pick module. At the distribution centers of companies like CVS Pharmacy and Rite Aid Corporation, for example, goods are stored before being repackaged and shipped to individual stores.As the 2:23min-long video says at the outset, pick modules can have several elevated levels of materials that are handled by both automation and personnel. Although everything in the material handling industry is becoming more automated, separation of full stored cases into smaller, individual shipments is still being completed manually. The size of pick modules has been increasing over the years; in the past, you may have seen a floor plus one level system, then a floor plus two levels, and now it is not uncommon to see three or even four elevated levels. This increases potential hazards.As the video continues, it is of paramount importance that proper guarding is used from the ground up to protect structures, the product they hold and, most importantly, the people working within and around them. Rack upright columns can be difficult to replace and costly to repair because often the area has to be closed off, product has to be removed, and multiple sections need to be disassembled. These components are all dependent upon one another, so if one part fails, the entire system can fail.The video highlights three “easy and affordable” solutions: Free-standing pallet rack column protectors Post cushions Bumper guardsHowever, ProGMA members offer a variety of products for ground-level protection including guardrails, bumper guards, column protectors, bollards, rack guards, and product containment enclosures  (i.e., wire mesh or netting); and for upper-level protection, such as side and back product containment enclosures (wire mesh or netting) to prevent products from falling below.What does ANSI say?The video continues, and quotes American National Standards Institute (ANSI) 6.4.3, which states that “…any gate that provides an access opening through the guards for the purpose of loading and unloading material onto a work platform shall be designed such that the elevated surface is protected by guards at all times. Gates that swing open, slide open, or lift or leave an unprotected opening in the guarding are not acceptable.”However, it is important to note that there are many mezzanines that were installed before the ANSI standards were created that used more conventional gates, such as removable, sliding, or swinging systems—and that is the same for pick modules. Systems can be retrofitted to achieve conformity with current standardization. There is no grandfather clause for ANSI (or OSHA) so all systems whether new or old should follow their guidelines. Note that many of the protective guarding products found in the video and on the ProGMA site are easily retrofittable to these older systems.As the video stresses, only dual-gate systems should be used. The same gates used on a pick module are also the preferred method for securing all elevated pallet drop areas whether they are in pick modules, on mezzanines, or on elevated work platforms such as storage or production / blending areas. The ANSI standards that recommended the use of dual-gate systems were written specifically for elevated work platforms and since a pick module is a type of elevated work platform that should be applied.The video demonstrates how a dual-gate system uses two counterbalanced and interconnected gates that are configured so when the first gate at the ledge is open, the second gate behind the pallet is closed. Fixed guarding on the sides—often the frame of the pallet rack in a pick module—prevents access into the side of the areas. This allows material to be loaded into the area while keeping employees a safe distance from the ledge and the material. When the rear / operator gate is opened, the ledge gate automatically closes, maintaining a barrier at the ledge while the pallet is accessed and picked. This creates what ProGMA calls a controlled-access area so there is always a barrier between the worker and the ledge.For information, ProGMA members that manufacture such solutions include Mezzanine Safeti-Gates Inc., Wildeck, and Heartland Engineered Products. Although companies still provide swing gates for pallet drop areas where a single pallet is loaded and staged, they are not an acceptable solution according to ANSI and could potentially create a situation where they are in violation of OSHA code.A self-closing swing gate, also featured in the video, should only be used when integrated with pallet flow lanes where multiple pallets are loaded into the system. The pallet flow lanes are pitched so the pallet rolls into the storage area. This allows the gate to immediately close once the pallet is loaded.  By comparison, when used for a single pallet position without flow rails, the staged pallet would hold the swinging gate open, preventing it from closing.For securing multiple deep pallet flow lanes, a dual-gate system is the preferred safety method because not only does it make sure a barrier is in place all times for fall protection, but it also keeps people out of the pallet flow lanes when pallets are being loaded. The two types of incidents we see in these areas are falls from the ledges and pallets being pushed into the legs of employees who have entered the lane. Only the dual-gate system keeps people out of the lanes when the lane is being loaded. The self-closing swing gate, however, does secure the ledge for fall protection.Hand in gloveOftentimes, a safety aspect can be used to increase productivity. For example, the self-closing swinging gate on pallet flow lanes will allow pallets to be quickly loaded into the system. Any time the lift truck operator wants to load a pallet into the area, they just push the pallet through the swinging gates. The dual-gate system has the potential of the gates being in the incorrect position for loading, meaning that the ledge gate is closed when the lift truck is trying to replenish pallets into the area. So they can go to load but a barrier is in place preventing them from doing so.A user can power operate these gates for remote operation but often this isn’t feasible due to the number of areas. Manual operation can actually create a safer and faster environment. The position of the gates in a dual-gate system can be used as a signal between the picker up on the platform and the lift truck operator below. In other words, when the ledge gate is closed that means the picker is picking from the pallets or the area doesn’t need to be replenished.When the picker has finished in that bay or when they notice the pallets need to be replenished in that bay, they just manually close the gate near them, which opens up the ledge gate. Now the lift truck operator can look up and see which areas are safe and ready to be replenished. This is an example of a safety system helping communications among the different workers.In conclusion, it’s evident that, despite automation, people remain at the center of activity in and around pick modules. ProGMA and its members are a one-stop-shop for leading safety solutions, whether it be for preventing hazards associated with falling boxes, product, or workers; or structural protection of the system itself from impact. As the video serves to reiterate, even in automated systems there are still people moving around the facility, either on ground level or on the elevated levels. Even if people are not used for the picking of material, there are areas where empty pallets or totes are removed that need to be guarded.The product-centric video doesn’t feature specific brands, but free-standing pallet rack column protectors, post cushions, and bumper guards are available from ProGMA members including Adrian’s Safety Solutions, A-Safe USA, Bluff Manufacturing, Boplan, DamoTech, Folding Guard, Husky Rack & Wire, Heartland Engineered Products, Jesco, McCue, Slowstop Guarding, SpaceGuard Products, Steel King, Troax, VisiPlas, Wildeck, and WireCrafters.Costs range from inexpensive, light-duty products to more expensive, heavy-duty solutions. Importantly, talking with the manufacturer about the application will help source the right product/s for the facility. No two pick modules or applications are completely alike and that’s what the member companies of the ProGMA are here to help with.The ProGMA website—mhi.org/progma—features details of 22 member companies and hundreds of solutions to help companies with older systems find protective guarding solutions to update / upgrade their pick module system.See the latest video and others in the series at mhi.org/progma/videosShould you be using a ProGMA member to enhance the safety and productivity of your pick modules?About ProGMAThe Protective Guarding Manufacturers Association (ProGMA) members are the industry’s leading suppliers of fixed protective guarding products designed to protect personnel, equipment, and inventory in industrial facilities. Member companies meet regularly to review, discuss, and revise the standards for design and performance of protective guarding products used in the material handling industry. ProGMA member companies are committed to the development, maintenance, and publishing of industry standard specifications for these systems. Visit the website at mhi.org/progma.About MHIMHI is an international trade association that has represented the material handling, logistics and supply chain industry since 1945. MHI members include material handling and logistics equipment and systems manufacturers, integrators, consultants, publishers and third-party logistics providers. MHI offers education, networking and solution sourcing for their members, their customers and the industry as a whole through programming and events. The association sponsors the ProMat and MODEX expos to showcase the products and services of its member companies and to educate manufacturing and supply chain professionals.Contact for editorial enquiries: Ashley Skidmore, askidmore@mhi.org or 704-676-1190

Courtesy of The Lift Manufacturers Product Group (LIFT)

Performing work within the best and preferred work zones shown below facilitates productivity and comfort.  Work is safest when lifting and reaching is performed in these zones.  Working outside these work zones results in non-neutral postures that may increase the risk of injury.  It is particularly important to perform heavy lifting tasks within the best work zone.